"Czero is one of the best companies I have worked with for analysis and simulation; including dynamic modeling, CFD and FEA. Their deep expertise and comprehensive quality system ensure accurate results. Czero's project management is excellent, providing clean concise information on progress, schedule and budget. Czero is a go-to source for projects ranging from analysis and simulation to prototype product development and testing. They deliver strong solutions to the challenges faced by Offshore and Subsea markets."
Modeling and Simulation Capabilities
Our Modeling and Simulation capabilities are divided into three broad sets:
MATLAB/Simulink Dynamic Modeling
Finite Element Analysis (FEA) Modeling
Computational Fluid Dynamics (CFD) Modeling
Often these capabilities are combined to provide a complete analysis of the system or component. CFD and FEA simulations are used to examine the detailed physics behind a design which may include complex flow patterns, chemical processes, mechanical loads, thermal stresses, and magnetic forces. The information derived from these detailed simulations is invaluable to understanding the performance of the system or component. Frequently, the information from the detailed analyses is used in a MATLAB/Simulink model enabling the analysis for a larger system.
Czero can develop and build dynamic simulations of your system that can be used for controls development and design exploration (i.e. model-in-the-loop, software-in-the-loop, and hardware-in-the-loop), so testing, debugging, and optimizing of the sensors, actuators, and control algorithm can be done accurately yet quickly and less expensively, with a decrease of risk of damaging hardware, and knowing your system’s performance before expensive testing begins.
Custom-built tools
We have many projects that require modeling tools beyond what is available in commercial software, so we develop our own. While we could purchase software to meet individual necessities – to model a chemical process, to create a physical model, or to generate a controller model – we have found that often the software does not play well together.
Therefore, we develop our own tools to perform these highly complex integrations. Case in point, Czero has developed a set of custom blocks in MATLAB/Simulink to support projects that require tracking of multiple fluid species, with phase changes and chemical kinetics. Because they were built from the ground up, they are customizable for just about any combination of species and ranges of pressure and temperature. Czero can leverage this library of tools for any project, reducing cost and development time, while customizing them for a client’s specific needs.
Advanced MATLAB Simulink Multi-Species Multi-Phase Block Set
Czero Engineering Overview
Czero Capabilities
Software & Tools
Focused analysis projects
While often our analysis and modeling is part of a larger design project, we also offer our capabilities for focused workscopes where the analysis model is the end result. This helps companies who have overloaded internal teams get through an analysis crunch, have a highly focused question to answer, or lack a particular internal capability and aren't ready to hire a full time person or team to fill that gap.
For example, we've assisted with FEA stress analysis of truck frames for a major OEM supplier, joined an internal coding team for an in-house data visualization tool, run CFD cases to provide recommendations for boosting hydraulic radiator fan power, set up a dynamic model of a transmission, and used a complex FEA model to determine root cause of a cracking compressor head.
Training Courses
Czero provides a comprehensive range of training options to meet all your needs. Whether you're looking to gain a better understanding of specific topics or require customized training, we have you covered. We offer both personalized one-on-one sessions and group training. Based on your preferences, we can deliver training online through synchronous learning or in-person at your office. Reach out to us to discuss your requirements, and together, we’ll explore the best solutions for you.
Please inquire about how we can assist you with training.
FEATURED PROJECTS
A full range of capabilities
- 3D multi-physics modeling
- 1D dynamic modeling
- Multi-species multi-phase gas and liquid dynamics
- Computational Fluid Dynamics (CFD)
- Finite Element Analysis (FEA)
- Electrical and magnetics modeling
- Thermodynamic analysis
- Electrochemistry
- Chemical processes
- Heat transfer
- Combustion
- Rigid-body dynamics
Software & Tools
- ANSYS
- Fluent CFD
- CFX CFD
- FEA
- MATLAB/Simulink/Simscape
- STAR CCM+
- Converge
- FEMM
- GT-SUITE
- Solidworks Simulation
- EES
- REFPROP (NIST)
- Bentley AutoPIPE
Example projects
- Fuel cell dynamic models for Solid-Oxide Fuel Cells (SOFC) and Proton Exchange Membrane (PEM)
- Transmission and powertrains dynamics
- Fuel injector mechanical and fluid dynamics
- Actuator electromagnetics and mechanical dynamics
- Refrigerant / vapor compression cycles
- Engine modeling including manifold dynamics and in-cylinder combustion
- Thermodynamics of gas cycles
- Thermal management of batteries
- Structural validation FEA of part and assembly stresses
- High-temperature, time-dependent FEA of elastomerics and polymers
- Compressed air energy storage / bottoming cycles / power generation
- Electromechanics / electrohydraulic actuators
- Vehicle and suspension dynamics
Analysis of complex dynamic systems
From day one, we have been a “measure twice, cut once” company. Our modeling and simulation engineers collaborate closely with the design and controls teams to model, test, and iterate to get your design right before it gets built. We recover the extra investment in simulation later in the development process through reduced redesigns. Targeted modeling and simulation up front expedite the best, most reliable design for your innovation.
Providing insight and checking the corner points of operations
Using a variety of sophisticated simulation tools, we model and predict how your design will work not only under ideal conditions but also as things change. During the course of the detailed analyses, our engineers develop deep knowledge of how the systems works, what it is sensitive to and what will and will not work. By checking the sensitivity of the system and involving system and controls engineers early in the design process, we ensure your final product will work well for the full range of conditions it may experience.
We understand this knowledge is invaluable to our customers and for their designs. Knowing our customer’s needs, we can provide not only an optimal solution, but also tradeoffs between various design inputs and easily present these for a deeper understanding of the interactions for various operating parameters. We want our customers to fully understand how their system works, have explanations for any non-intuitive behavior, and have communicated the results clearly to the customer. The results are never a single answer, but often a table, a set curves and other graphics to help understand not just the benefits of a chosen design, but all the tradeoffs as well.
Simulation for demanding applications
Analyzing and designing complex systems with unconventional and demanding requirements and high-performance specifications is a big part of what Czero does. We help our customers solve problems where other methods have failed. As just a few examples, we design hydraulic valves that respond in sub milliseconds, optimize performance in high-temperature thermal energy storage systems, evaluate the efficacy of cooling systems that operate in low-gravity environments, hybridize heavy-duty equipment, solve valve chatter issues, determine root causes for cracking parts, and uncover the limiting factor in the power output of hydraulic systems. In many applications, more traditional engineering practices simply aren’t enough. The system is too transient, temperatures and pressures too high, or the system is too novel.
Frequently Asked Questions
What modeling and simulation services does Czero offer?
Czero provides three integrated modeling and simulation capabilities: MATLAB/Simulink dynamic modeling, finite element analysis (FEA), and computational fluid dynamics (CFD). They are usually combined. CFD and FEA resolve the detailed physics of a component, including flow patterns, chemical processes, mechanical loads, thermal stresses, and magnetic forces. Those results then feed a Simulink model that predicts behavior at the system level. The same dynamic models support controls development through model-in-the-loop, software-in-the-loop, and hardware-in-the-loop (MIL/SIL/HIL) simulation. When commercial software cannot couple the physics a project needs, Czero builds its own tools.
When should I use CFD, FEA, or 1D dynamic modeling?
Match the tool to the question. Use 3D CFD when you need to see inside the fluid volume: recirculation zones, low-pressure regions, hot spots, cavitation, or reacting flow in combustors, engines, and reactors. Use FEA for stress, buckling, vibration, fatigue, thermal stress, impact, and magnetics. Use 1D Simulink/Simscape models to debug product issues, size equipment, predict operational issues, and develop control strategies at the system level. The tools hand off to each other. CFD results can be tabulated for a system model, such as valve loss coefficients versus flow rate and temperature, or flow forces on an injector needle versus flow rate and lift. A solenoid control valve model, for example, combines CFD of the valve with magnetic FEA of the solenoid to capture coil current rise time, magnetic force versus current and armature gap, flow forces, and bounce and stiction at the hard stop.
What are MIL, SIL, and HIL simulation, and what makes a plant model real-time capable?
MIL, SIL, and HIL simulation test a controller against a dynamic plant model instead of physical hardware. In model-in-the-loop, the controller is itself a model that runs against the plant model. In software-in-the-loop, the compiled controller code runs against the plant model on a host computer. In hardware-in-the-loop, the plant model runs on a real-time simulator and the physical controller behaves as if it were connected to real hardware. The core challenge is that the plant model must represent the physics accurately while meeting controller rates and the computational limits of the HIL hardware. Czero has deployed plant models on Speedgoat, dSPACE, ETAS LABCAR, and NI platforms, and is a MathWorks partner. The payoff is that controls can be tuned and validated, including response to sensor faults, disturbances, and operation outside the normal safe envelope, before they touch hardware that could be damaged.
How does Czero validate the accuracy of its simulation models?
Czero builds physics-based models, then calibrates and validates them against measured data. On a HIL plant model of the Abrams gas turbine and powertrain built to support the US Army Ground Vehicle Systems Center, the engine model used real-gas properties from NIST REFPROP because ideal-gas approximations are insufficient across the turbine’s operating range. It was automatically calibrated against a large set of measurement data using an automated tuning method. The tracked-vehicle model included dynamic weight transfer and 56 discretized contact patches (four under each of 14 drive wheels), and the plant models were validated against high-quality dynamometer data, showing a high degree of correlation. Czero also checks sensitivity and the corner points of operation, so results cover the full range of conditions a product will see, not only the design point.
What simulation software does Czero use?
Czero chooses the tool that fits the physics and the client’s workflow. For CFD, the main tools are Siemens STAR-CCM+ and ANSYS Fluent and CFX, with CONVERGE for in-cylinder combustion CFD. ANSYS is preferred when a problem couples fluid-structure or thermal-structure physics. FEA uses ANSYS. System-level modeling uses MATLAB, Simulink, and Simscape. Czero’s software list also includes SolidWorks Simulation, FEMM, GT-SUITE, EES, NIST REFPROP for real-gas properties, and Bentley AutoPIPE. Large FEA cases can run on Rescale cloud computing rather than being limited by in-house hardware.
Can Czero model multi-species, multi-phase, and reacting flows in Simulink?
Yes. Czero developed a custom MATLAB/Simulink block set that tracks multiple fluid species with phase changes and chemical kinetics. Because the blocks were built from the ground up, they can be customized for nearly any combination of species and ranges of pressure and temperature, and they can run in real time for HIL use. Supported physics includes incompressible and compressible liquid flow, ideal and real gas flow, simple combustion with heat release, equilibrium chemistry, rate-based chemistry, heat transfer, and electrochemistry based on Nernst potentials and ohmic losses. Past models include solid-oxide and PEM fuel cells, gas reactors, refrigerant cycles, and compressed air energy storage. The multi-species multi-phase block set whitepaper has the details.
Can I hire Czero for a standalone analysis instead of a full design project?
Yes. Czero takes focused workscopes where the analysis model is itself the deliverable. That suits teams with an overloaded internal group, a narrow question to answer, or a capability gap they are not ready to hire for. Past examples include FEA stress analysis of truck frames for a major OEM supplier, CFD cases to recommend ways to boost hydraulic radiator fan power, a dynamic model of a transmission, joining an internal coding team on a data visualization tool, and using a complex FEA model to find the root cause of a cracking compressor head. For CFD and FEA, engagement options include standard consulting, design by analysis, and knowledge transfer, where Czero hands over a model as a learning template and explains how it was built.
What kinds of hard or unconventional problems does Czero simulate?
Czero focuses on problems where conventional engineering practice runs out: systems that are too transient, too hot, too high-pressure, or too novel. Examples include hydraulic valves that respond in sub-milliseconds, optimization of high-temperature thermal energy storage, cooling systems that operate in low-gravity environments, hybridization of heavy-duty equipment, valve chatter, the limiting factor in hydraulic power output, and root causes of cracking parts. Other modeled systems include fuel injector mechanics and fluid dynamics, engine manifold dynamics and in-cylinder combustion, battery thermal management, vapor compression cycles, high-temperature time-dependent FEA of elastomers and polymers, and vehicle and suspension dynamics.
What do I receive at the end of a simulation project?
You get answers plus the reasoning behind them. Czero’s results are rarely a single number. They typically include tables, curves, and graphics that show the trade-offs between design inputs and how sensitive the system is to operating parameters, along with explanations for any non-intuitive behavior. Depending on scope, deliverables include an analysis report and recommendations for fixing issues the analysis reveals, and Czero can hand over a model as a learning template. Czero also offers one-on-one or group training, online or in person, including ANSYS Mechanical courses on linear and nonlinear statics, hyperelasticity and viscoelasticity, fatigue, heat transfer, acoustics, and linear and nonlinear structural dynamics.
Does Czero also build and test hardware, and who owns the IP?
Yes. Modeling and simulation at Czero usually sits inside a larger development program that includes mechanical design, controls, and prototype build and test, with in-house machining and fabrication. The approach is analysis-led: model first, then build, so problems are found in simulation instead of in hardware. Czero’s work typically spans technology readiness levels (TRL) 3 to 6, from concept feasibility through a working prototype demonstration. In almost all engagements, the intellectual property assigns to the client. To discuss a project, contact Czero.
- Horst Moll, Former First Chief Engineer, Aker Solutions
"Nexceris has been working with Czero since 2018 to develop and demonstrate a 50-kW scale hybrid power system for a government customer (ARPA-E). Czero led system design and controls development, and currently is leading system construction and testing work on the project. Czero engineers are extremely talented, innovative, detail oriented and responsive. I have thoroughly enjoyed our collaboration and provide my highest recommendation."
- Scott Swartz, Founder and CTO, Nexceris
"PDC Machines- a compression and refueling technology provider to the world’s emerging hydrogen economy has been working with Czero for over 6 years on a combination of greenfield new technology and incremental technology improvements to our product. They have been able to take our napkin sketch frameworks and work with our team to deliver minimum viable product to complete solutions which are efficient, marketable and in many cases patentable. Their clear and simple approach to partnership- working as part of one team PDC staff is why I believe in the growing foundation we started 6 years ago."
- Kareem Afzal, Executive Chairman, PDC Machines
"We chose Czero since they have a stellar reputation for innovation and expertise in the automotive industry. They also have a proven track record and prior history with the original inventor [of Onboard Dynamics natural gas refueling technology]—who is on our team—that has already resulted in huge successes in meeting critical milestones and performing to expectations."
- Rita Hansen, CEO Onboard Dynamics
"I have a >$1M US Department of Energy research effort for which I was understaffed and lacking specific subject area expertise. Czero was able to engage last minute to displace a well-known automotive engineering company at a fraction of the price. Over a year into the project, Czero has continued to be responsive and trustworthy; their engineering performance has contributed significantly to an increase in project funding from the sponsor. As the project principal investigator, selecting Czero as an engineering services company has been one of the best decisions I have made."
- Chris Hagen, Assistant Professor, Energy Systems Engineering Oregon State University – Cascades
"Czero’s work with us to fully understand the requirements of the end product for the new reactor engine system has been instrumental in developing a completely new, innovative system. From these requirements, they were able to quickly come up with multiple concepts for vetting against the tough project objectives, which include not only technical feasibility but also aggressive cost targets. The in-depth simulation and analysis of the various concepts that Czero did ahead of time has built tremendous confidence we are going down the right path."
- Devin Halliday, Principal Investigator, Gas Technology Institute
"Czero’s ability to work with our engineers in developing innovative, ground-breaking technology has been a great benefit to the SuperTurbo development. We have placed a lot of trust in Czero’s ability to deliver and have not been disappointed. They are a top-shelf organization."
- Tom Waldron, Executive VP, SuperTurbo Technologies
“My initial request to Czero was to develop software and the associated controller needed for a very important competitive assessment of our product. Due to the nature of the project, I needed the work to be accomplished and in my customers hands within 2 months, which was a very aggressive necessary timeline for this level of work. Not only did Czero get the software and ECU requirements done to spec, but the system was delivered to my customer ahead of time to support the testing. The expertise, timeliness, and quality of the Czero solution was outstanding!”
- Bradlee J. Stroia Ph.D., Stanadyne Operating Company LLC
"We’ve had an absolutely fantastic, positive experience with Czero and I wholeheartedly endorse them. They are more than a typical ‘throw it over the fence’ engineering consulting firm, as Czero not only develops a strong understanding on the background of the project, but they also think along the way and offer suggestions and ideas beyond the scope of the simple engineering contract deliverables. And, they deliver, too. They are really solid, outstanding people."
- Steve Kloos, Former CEO AquaHydrex
"The engineers on the Czero team were proactive problem-solvers from our first introduction. They quickly applied the full breadth and depth of their engineering team’s impressive intellect to determine the most efficient and cost effective system to maximize the energy-harvesting capabilities of Brown’s concept.
They were remarkably objective in their trade studies to find the best solution, favoring a simpler mechanical solution over their greatest strength: advanced hydraulics. They walked us through potential failure modes of each system, and educated the team about the pitfalls of component scalability. In addition to their technical solutions, Czero did an excellent job conveying their thought process and analysis to the Brown team with clear graphs, diagrams and presentations, which streamlined decision-making.
Czero added tremendous value to the Brown project and was a pleasure to work with. We look forward to putting our heads together on future projects."
- Tom Derecktor, CEO
"Czero has been an invaluable and integral part of our program. From component and subsystem design to detailed system performance analysis, Czero’s integrated engineering approach has allowed us to develop elements quickly to meet the very ambitious schedule challenges imposed by our U.S Department of Defense contract."
- Scott Frazier, Co-founder and CEO
"Czero has been a valuable strategic partner in helping FACTOR[e] startups advance technologies quickly while staying lean during their crucial first two years. We know Czero’s agility, creativity and process. We trust their team. We’ve seen their technology insights and the business value of what they deliver."
- Morgan DeFoort, CEO
"As we move from R&D to commercialization, Czero is providing top-notch engineering support to our team, transforming our ideas and concepts from prototype designs to viable commercial products. Czero really digs into the requirements before starting the design process, enabling us to easily collaborate on design options that optimize our product designs to meet market demand and ensure customer satisfaction. Without hesitation, we recommend Czero to anyone wanting to accelerate R&D and product development."
- Steve Witt, CEO, OptiEnz Sensors
"Czero understood our test objectives very quickly and communicated systematically to define the test procedure, scale model details, and test fixture that fulfilled all test requirements quickly and safely. They creatively utilized off-the-shelf items in the scale model to keep its cost low and provided a clear, concise report—including useful insight—within a week of test completion. Helix is very pleased with the service provided by Czero."
- Roy Cottrell, Engineering Manager, Helix ESG
"With extensive experience in engine systems design, Czero played a vital
role in helping Logimesh expedite concept-to-prototype development and
testing of our award-winning Logimote engine health monitoring platform."
- Bill Gillette, President & CEO, Logimesh Technologies, LLC
"Czero was the right partner to help us design our custom grist bin and bag intake station. They found the perfect balance between a properly engineered solution, a cost effective solution, and an aesthetic solution."
- Bryan Hermann, Technical Director, K-MALT
"The true sign of individual or organizational dynamism is the willingness to take risks. It signals real confidence in capabilities and know-how, the flexibility and creativity to explore and test new solutions, and guts to do what it takes to deliver under real economic and technical uncertainty. Czero epitomizes those characteristics and combines them with old-fashioned integrity and reliability. Needless to say, their engineering and technical capabilities are superb. As a young company commercializing real black-box technology, we've entrusted Czero with taking responsibility for critical design and engineering tasks for which there are no precedents, i.e. it has never been done before. They have delivered, under demanding time and resource constraints, and set a very high bar. Culturally and otherwise, they are an ideal partner for young startups who need deep-dive, blank-slate engineering solutions. I would recommend them to anyone."
- Richard Kinsman, former President & CEO, CO2 Nexus Inc. (now Tersus Solutions)
"Czero was an insightful and very technically proficient group that were instrumental in helping us develop our technology. They were very quick studies to understand the fundamental challenges we faced and design/build solutions around them. Top qualities: Great Results, Personable, Good Value.
- Doug Henston, Former CEO, Solix Biofuels
"Czero understands technology development from the back-of-the-napkin stage to the product launch stage. I've never met a team who is more capable of keeping the end-product vision in mind during the early stages of engineering."
- Sam Jaffe, CEO, Panea Energy
"Czero provided a custom engineering solution to our need to convey conceptual functionality. Their approach was creative, effective, high quality and fast. Highly endorsed."
- Rick Dunagan, Partner, Symbiotic Solutions
"To work with Czero is nothing short of a privilege. Stemming from their excellent credentials and strong analytical aptitude, they consistently translate complex technical situations into plain English to allow multidisciplinary group to function together seamlessly."
- Nick Rancis, Co-Founder and Principal, Tierra Verde Consulting LLC
"I was extremely impressed with how quickly Czero understood the needs and intent of the bearing housing design and how responsive they were in completing the drawing package."
- Scott Taylor, VP of Engineering, TMA Global Wind Energy Systems